Liquid level controller with manual tripping device

ABSTRACT

A liquid level controller assembly for a vessel is disclosed. The liquid level controller assembly includes a float positionable within the vessel such that the float is moveable in response to liquid level changes. A lever is connected to the float such that the lever moves in response to movement of the float. An extension member is connected to the lever and positionable to be manually reached by an operator standing at ground-level to permit the operator to selectively move the lever by actuating the extension member when the lever is positioned at a height that causes the lever to be out of manual reach of the operator while the operator is standing at ground-level.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a liquid level controller assembly, and more particularly, but not by way of limitation, to a liquid level controller assembly having a manual tripping device for testing the functionality of a liquid level controller from ground-level.

2. Brief Description of Related Art

A primary concern with above-ground storage tanks used for storing fluid, such as oil, is overflow or spillage of fluid from the storage tanks. Storage tanks are typically equipped with a control device such as an alarm, signal light, or valve for alerting operators of liquid level changes within the tank and/or controlling liquid levels within the tank to prevent hazardous spills from occurring. High-level liquid level controller assemblies are typically used to detect when the liquid level in the storage tank reaches a predetermined level and typically include a float and a liquid level switch. When the tank reaches the predetermined level, the float is raised thereby tripping the liquid level switch, which may be in the form of a pilot valve or an electric switch. The liquid level switch in turn activates an alarm, such as a horn or a signal light, or a fluid control device, such as a control valve.

A problem that may, nevertheless, be encountered is that the liquid level switch may fail or debris, such as trash or solids, may accumulate around the float causing the liquid level controller assembly to malfunction. In order to ensure proper functioning of the liquid level controller assembly, an operator is often required to manually actuate the liquid level controller assembly. However, because the liquid level controller assembly is usually positioned at the upper end of the storage tank, the operator must climb the storage tank to manually trip the liquid level switch of the liquid level controller assembly. This action of climbing the storage tank to manually trip the liquid level switch is time consuming and constitutes a safety concern for the operator.

To this end, an improved liquid level controller assembly is needed for manually testing the functionality of the liquid level controller from ground-level thereby reducing the time and safety concerns associated with testing the functionality of the liquid level controller. It is to such a liquid level controller assembly that the present invention is directed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a liquid level controller assembly constructed in accordance with the present invention shown mounted to a vessel.

FIG. 2 is a partially cut-away, side view of the liquid level controller assembly of the present invention.

FIG. 3 is a partially cut-away, side view of the liquid level controller assembly of the present invention.

FIG. 4 is a partially cut-away, bottom view of the liquid level controller assembly of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, and more particularly to FIGS. 1 and 2, a liquid level controller assembly 10 constructed in accordance with the present invention is shown mounted to a vessel 12. Liquid level controller assemblies are well known in the art for the purpose of liquid level control within the vessel 12 or as a component of Hi-Lo level alarm systems to alert an operator 14 as to the liquid level inside the vessel 12. The vessel 12 is of the type positioned above-ground and includes a top wall 16, a bottom wall 18, and a sidewall 20, all cooperating to define an interior space 22 (FIG. 2). The vessel 12 may be, for example, a storage tank for storing any type of fluid including, for example, water, oil, or a combination thereof.

The liquid level controller assembly 10 includes a float assembly 24 (FIG. 2) and a switch assembly 26. In a manner well known in the art, movement of the float assembly 24 actuates the switch assembly 26, which in turn causes a signal or control device (not shown) to be actuated. Periodically, operability of the float assembly 24 and the switch assembly 26 should be tested. Because the liquid level controller assembly 10 is generally mounted on the vessel 12 at a height that causes the liquid level controller 10 to be out of reach of the operator 14 when the operator 14 is standing at ground-level, the operator 14 is required to climb the vessel 12 to access and manually actuate the liquid level controller assembly 10. As mentioned above, the act of climbing the vessel 12 to manually actuate the liquid level controller assembly 10 is time consuming and places the operator 14 at risk of injury.

To alleviate the concerns associated with climbing the vessel 12 to manually actuate the liquid level controller assembly 10, the liquid level controller assembly 10 of the present invention includes an extension member 28 which extends downwardly from the float assembly 24 to permit the operator 14 to manually actuate the float assembly 24 while standing at ground-level.

Referring now to FIGS. 2-4, the float assembly 24 includes a housing 30, a pivot assembly 32, a float arm 34, a float 46, and a lever 38. The housing 30 functions to enclose and support the pivot assembly 32 and the lever 38. The housing 30 is adapted to be secured to the sidewall 20 of the vessel 12. In the embodiment illustrated in FIGS. 2-4, the housing 30 is provided with a flange 40. However, the housing 30 may be secured to the vessel 12 with other types of connectors. The housing 30 is preferably constructed of any rigid material, such as steel or bronze, so as to enclose and support components located within the housing 30. The housing 30 may be any shape or size so long as the components are capable of being enclosed therein. The housing 30 is provided with an opening 42 in a lower portion thereof for receiving the extension member 28. The position of the opening 42 will be described in greater detail below.

The pivot assembly 32 is enclosed within and connected to the housing 30 to provide for pivotal movement of the float assembly 24 within the vessel 12. The pivot assembly 32 includes a trunnion 44, a retainer bushing 46, a spring 48, a screw 50 and a lock nut 52. The trunnion 44 (FIG. 4) is a shaft with a block member for connection with the float arm 34. The trunnion 44 is rotatably positioned in the housing 30 and secured thereto with the retainer bushing 46. The trunnion 44 is characterized as having a first end portion 54 and a second end portion 56. The first end portion 54 is rotatably positioned in a recess 57 of the housing 30 and the second end portion 56 extends from the retainer bushing 46 and is connected to the lever 38 with the screw 50 and the lock nut 52.

Shown in FIGS. 2-4, the lever 38 is a substantially double L-shaped member connected to the second end 56 or the trunnion 44 so that the lever 38 moves in response to rotation of the trunnion 44. The lever 38 includes a first L-shaped arm 58 and a second L-shaped arm 60 connected to one another at a U-shaped junction 62. The first L-shaped arm 58 has an opening 64 (FIG. 4) for receiving one end of the extension member 28. The opening 64 is preferably aligned with the opening 42 of the housing 30. The spring 48 is shown positioned between the housing 30 and the lever 38 to bias the lever 38 in a first or non-actuating position (FIG. 2). The first L-shaped arm 58 functions to actuate the switch assembly 26 upon the lever 38 being caused to move from the first position (FIG. 2) to a second position (FIG. 3) in response to movement of the float assembly 24.

The float arm 34 has a proximal end connected to the trunnion 44, and the float arm 34 extends from the housing 30 into the interior space 22 of the vessel 12. The float 36 is connected to a distal end of the float arm 34. The float 36 is preferably a hollow member constructed of stainless steel. However, it should be understood that any material which permits the float 36 to float on the surface of a liquid such that the float 36 is moveable in response to liquid level changes within the vessel 12 may be used to construct the float 36.

The switch assembly 26 includes a liquid level switch 68 and a switch arm 70. The liquid level switch 68 is adapted to be mounted to the housing 30 to permit the switch arm 70 to be positioned between the first and second arms 58 and 60 of the lever 38 such that movement of the lever 38 from the first position (FIG. 2) to the second position (FIG. 3) in response to upward movement of the float 36 actuates the switch arm 70 (FIG. 3). The liquid level switch 68 is shown in FIGS. 2-4 as being a pneumatic pilot valve. However, it will be appreciated that the liquid level switch 68 may be an electric or hydraulic switch. The liquid level controller assembly 10 illustrated herein is commonly referred to as a direct acting switch wherein the raising of the float 36 actuates the switch arm 70. However, it will be appreciated that the liquid level controller assembly 10 may be configured to be indirect acting wherein the switch arm 70 is actuated when the float 36 drops.

The extension member 28 may be any elongated device that may be connected to the lever 38, or any other portion of the float assembly 24, and extended downwardly to be manually reached by the operator 14 while the operator 14 is standing at ground-level to permit the operator 14 to selectively move the lever 38 by actuating the extension member 28 when the lever 38 is positioned at a height that causes the lever 38 to be out of manual reach of the operator 14 while the operator 14 is standing at ground-level. The extension member 28 may be constructed of any rigid or flexible material so long as the extension member 28 has a sufficient length to be accessible by the operator 14 while standing at ground-level. For example, the extension member 28 may be a rope, a chain, a wire, a cord, a cable, a string, a strap, a bar, or a tether. In one embodiment, the extension member 28 has a proximal end 72 extended through the opening 42 of the housing 30 and secured to the first arm 58 of the lever 38. The proximal end 72 of the extension member 28 is shown connected to the lever 38 by extending the proximal end 72 of the extension member 28 through the opening 64 of the first arm 58 and securing the extension member 28 with a suitable connector, such as a wire clamp 74. To facilitate grasping of the extension member 28, the extension member 28 may be provided with a handle 76 at a distal end 78 of the extension member 28.

As best illustrated by FIGS. 1-3, to test the functionality of the liquid level controller assembly 10 while standing at ground-level, the operator 14 manually grasps the extension member 28 and actuates the extension member 28. By grasping and applying a downward force to the extension member 28, the float assembly 24 is moved from the first position (FIG. 2) to the second or actuating position (FIG. 3) thereby causing the lever 38 to trip the liquid level switch 68. If the liquid level switch 68 is not tripped, or fails to actuate the peripheral devices, such as an alarm, signal light or control valve, the operator 14 may then be required to climb the vessel 12 and access the interior space 22 of the vessel 12 to repair the liquid level controller assembly 10. However, when installed on a vessel, such as the vessel 12, the liquid level controller assembly 10 provides the advantage of permitting the operator 14 to stand at ground-level to quickly and easily test the functionality of the float assembly 24.

From the above description, it is clear that the present invention is well adapted to carry out the objects and advantages mentioned herein as well as those inherent in the invention. While a presently preferred embodiment of the invention has been described for purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the spirit and scope of the invention disclosed and as defined in the appended claims. 

1. A liquid level controller assembly for a vessel, comprising: a float positionable within the vessel such that the float is moveable in response to liquid level changes; a lever connected to the float such that the lever moves in response to movement of the float; and an extension member having a proximal end connected to the lever and a distal end positionable to be manually reached by an operator standing at ground-level to permit the operator to selectively move the lever by actuating the extension member when the lever is positioned at a height that causes the lever to be out of manual reach of the operator while the operator is standing at ground-level.
 2. The liquid level controller assembly of claim 1 further comprising a liquid level switch having a switch arm positioned such that movement of the lever actuates the switch arm.
 3. The liquid level controller assembly of claim 1 wherein the extension member is flexible.
 4. The liquid level controller assembly of claim 3 wherein the extension member further comprises a handle connected to the distal end of the extension member.
 5. The liquid level controller assembly of claim 1 further comprising a housing connectable to the vessel and enclosing the lever, the housing having an opening therethrough for slidably receiving the extension member.
 6. The liquid level controller assembly of claim 5 wherein the opening is formed through a lower portion of the housing.
 7. A liquid level controller assembly in combination with a vessel containing a liquid, the liquid level controller assembly comprising: a float positioned within the vessel such that the float is moveable in response to liquid level changes; a lever connected to the float such that the lever moves in response to movement of the float, the lever positioned at a height that causes the lever to be out of manual reach of an operator while the operator is standing at ground-level; and an extension member having a proximal end connected to the lever and a distal end positionable to be manually reached by an operator standing at ground-level to permit the operator to selectively move the lever by actuating the extension member.
 8. The combination of claim 9 further comprising a liquid level switch having a switch arm positioned such that movement of the lever actuates the switch arm.
 9. The combination of claim 8 wherein the extension member further comprises a handle connected to the distal end of the extension member.
 10. The combination of claim 9 further comprising a housing connectable to the vessel and enclosing the lever, the housing having an opening therethrough for slidably receiving the extension member.
 11. The combination of claim 10 wherein the opening is formed through a lower portion of the housing.
 12. A liquid level controller assembly for a vessel, comprising: a float positionable within the vessel such that the float is moveable in response to liquid level changes; a housing connectable to the vessel; a lever positioned within the housing and connected to the float such that the lever moves in response to movement of the float; and an extension member having a proximal end connected to the lever and a distal end positioned on the exterior of the housing to permit an operator to selectively move the lever by actuating the extension member.
 13. In a method of testing the functionality of a liquid level controller assembly of the type wherein the liquid level controller assembly has a float positioned within a vessel, a lever connected to the float such that the lever moves in response to movement of the float and positioned at a height that causes the lever to be out of manual reach of an operator while the operator is standing at ground-level, and a liquid level switch having a switch arm tripped in response to movement of the lever, the improvement comprising: manually grasping and actuating an extension member connected to one of the lever and the float while standing at ground-level to cause the lever to move and thereby trip the switch arm of the liquid level switch. 